2. 2 .a & 2. 2.b plant location and layout
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Plant Location Plant Location And LayoutAnd Layout
Session2. ii & iii
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Plant Location And LayoutPlant Location And Layout
The efficient operation of a plant depends up on the proper selection of the site and lay out of the plant.
The following factor have a significant influence on the choice of location site and lay out.
Differentiation of factors between the problems of location of site :
Choose the general area1. Conduct detailed survey to find out possible site.
2. Final decision be taken on detailed factors.
Source: Study material on Industrial Engineering-II, By Andhra Pradesh Productivity Council, Chp. No.3, From Pg No. 1 to 27
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1. Integration with group companies
2. Availability of labor
3. Availability of housing
4. Availability of amenities
5. Availability of transport
6. Availability of materials
7. Availability of parking space
8. Availability of dirculation
9. Availability of services, gas-electricity, water, drainage and waste disposal
Factors which influence the Factors which influence the choice of Locationchoice of Location
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10. Stability of land & climate
11. Local building and planning regulation
12. Room for expansion
13. Safety requirements
14. Cost of sight
15. Political situation
16. Industrial climate (Labor)
17. Subsidies from Government
Factors which influence the Factors which influence the choice of Locationchoice of Location
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1. Identify the key factors.
2. Rank the chosen sites with appropriate weightage.
3. Examine all factors and rank them based on
importance – Rank factor by factor and not location
by location.
4. Multiply the ranking by the weightage factor. The
total indicates the desirability of the possible
location.
Selection of A Particular LocationSelection of A Particular Location
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Selection of A Particular Location – Selection of A Particular Location – A Hypothetical ExampleA Hypothetical Example
Factor Weight
A B C D EIntegration 0 - 0 - 0 - 0 - 0 - 0Labor 9 1
9
5
45
4
36
2
18
3
27Housing 6 3
18
3
18
2
12
5
30
1
6Amenities 6 1
6
2
12
4
24
5
30
3
18Transport 4 5
20
4
16
3
12
2
8
1
4Materials 4 4
16
1
4
2
8
3
12
5
20Car park 6 3
18
4
12
5
30
1
6
2
12Circulation 6 1
6
4
24
3
18
5
30
2
12
Possible Location
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Selection of A Particular Location – Selection of A Particular Location – Assessment of Possible Factory LocationAssessment of Possible Factory Location(1) (2) (3) (4) (5) (6) (7)
Services 5 1
5
2
1 0
2
10
5
25
4
20Land and Climate
2 4
8
2
4
5
10
3
6
1
2Planning Regulations
8 5
40
2
16
4
32
3
24
1
8Expansion 2 3
6
4
8
2
4
5
10
1
2Safety 0 -
0
-
0
-
0
-
0
-
0Cost 1 5
5
1
1
2
2
3
3
4
4Political Situation
0 -
0
-
0
-
0
-
0
-
0Special Subsidies
2 2
4
1
2
5
10
4
8
3
6Totals 161 184 208 210 141
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• Factors affecting the design of the plant.• Detailed design can be prepared by an architect with
a brief sent by the client which should indicate.
1. Accommodation required
2. Latest possible completion data
3. Quality / standards and expected life of the new building
4. Proposed site
5. Anticipated cost of plant.
Plant LayoutPlant Layout
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1. Size2. Head room required (height)3. Loads to be carried4. Access5. Lighting6. Ventilation and heating7. Services to be provided8. Waste disposal
Decision Considerations 1/2Decision Considerations 1/2
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9. Special process requirementsi. Temperature controlsii. Type of flooring vibrationsiii. Special security measuresiv. Special lighting needsv. Special amenities if any
10. Number of Floors
Decision Considerations 2/2Decision Considerations 2/2
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• Layout is the physical disposition of the plant and the various sections of the plant
• The layout will encompass both the location of the equipment within a specific department and location of different departments.
• Types of Layout– Product Layout– Process Layout
• The techniques of Layout are generally as discussed in work-study. However the process & Layout must be a creative one.
Plant LayoutPlant Layout
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1. Maximum flexibility
2. Maximum coordination
3. Maximum usage of volume (cubic space)
4. Maximum visibility
5. Maximum accessibility
6. Minimum distance of movement
7. Minimum handling
Criteria to be satisfied in a good layoutCriteria to be satisfied in a good layout
8. Minimum discomfort
9. Inherent safety
10. Maximum security
11. Uni flow
12. Visible routes
13. identification
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1. Reduced cost and process time through minimized material
handling.
2. Labor productivity through visible and open layout.
3. Easy accommodation of changes.
4. Maximum and better utilization of space.
5. Better quality and safer methods.
6. A conducive environment to motivate employees.
Advantages of a Good LayoutAdvantages of a Good Layout
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1. Collect all information needed
i. Type / quality/ quantity of work force
ii. Dimensional plan of space to be laid out
iii. Volume of work to be produced or material to be stored
iv. Operations, process, sequence and standard times
v. Equipment needed to carry out the production / operation
vi. Movement of material between the work station (quantity & method) and the frequency (to construct travel charts)
vii. Time for ageing, stabilizing, normalizing, e.t.c
Preparation of Layout 1/2Preparation of Layout 1/2
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viii.Quantity of material stores / sub stores in process storage etc & buffer stock
ix. Location of main stores and volumes to be stored
x. Lines of communication & fire exits
xi. Special security arrangements, burglars alarms, safety alarms etc.
xii. Inspection needs
xiii.Special needs for geographical location of specific section such as dispatch
xiv.Contingency arrangements for stand bye equipments.
Preparation of Layout 2/2Preparation of Layout 2/2
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1. String diagram
2. Flow Process chart
3. Travel Chart
4. Flow diagram
5. Multiple activity chart
6. Template Models
Tools used for preparing Plant LayoutsTools used for preparing Plant Layouts
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String diagram 1/6String diagram 1/6The string diagram is a scale plan or model on The string diagram is a scale plan or model on which a thread is used to trace and measure the which a thread is used to trace and measure the
distance traversed which has to be minimum by distance traversed which has to be minimum by •Workers•Material or•Equipment
during a specified sequence of eventsduring a specified sequence of events
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• Observe the clusters of points, pins, turning points.
• Also observe the grid lines which represent a measure of the distance between the points.
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Construction of a String diagramConstruction of a String diagram
• Step-1– Preparing a study chart
• Step-2 – Drawing a scale plan of the working area
• Step-3– Combining steps 1,2 to construct the final diagram
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Step-1Step-1:: Preparing a study chartPreparing a study chart
• Worker being studied is followed and all the points along the working areas are noted in a study sheet until a representative picture of the workers is obtained.
• Thus the movements are noted down for enough number of cycles so as to capture the actual work in terms of the journey made by the worker with their respective frequencies.
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Step-2Step-2:: Drawing a scale plan of the Drawing a scale plan of the working areaworking area
• Machines, benches, stores and all other points at which calls are made are drawn to scale together with doorways, pillars etc that effect the path movements.
• Then attachments like soft wood, composition board and pins are driven firmly at every point. Pins are driven also at turning points on the route.
• This ensure a shop floor environment which helps to do the study accurately.
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Step-3Step-3:: combining the steps 1 and 2combining the steps 1 and 2
• A measured length of thread is wound from the starting point of the movement of the worker and leading through all the points on the path of the worker in the same order noted in the step-1
• This results in a String diagram.
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Process activity symbolsProcess activity symbols
• Operation
• Inspection
• Transport
• Temporary storage or Delay
• Permanent storage
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Flow process chart 2/6Flow process chart 2/6
PurposePurpose::
To set out the sequence of the flow of a To set out the sequence of the flow of a product or a procedure by recording all the product or a procedure by recording all the events under review ( Inspection ) using the events under review ( Inspection ) using the appropriate process chart symbols.appropriate process chart symbols.
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Process chart symbolsProcess chart symbols
• Used to represent different types of activities or events.
• Very convenient, widely understood type of short hand, saves a lot of writing and helps in making the sequence of activities clear.
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Three typesThree types of of flow process chartsflow process charts
• Man type– Flow chart which records what the worker does
• Material type– Flow chart which records how material is handled or
treated
• Equipment type– Flow chart which records how the equipment is
used
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Man typeMan type flow process chart for dinner at a hospital flow process chart for dinner at a hospital
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Travel chart Travel chart 3/63/6
• A travel chart is a tabular record for presenting quantitative data about the movements of workers, materials or equipment between any number of places over any given period of time.
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Why Travel chart ?Why Travel chart ?
Although the string diagram is a neat and effective way of record the movement of worker or material for critical examination,
o they take long time to construct o look increasingly like a complex maze with
increasing complexity of movement paths
When the movement patterns are complex, the travel chart is quicker and more manageable to record.
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Travel chartTravel chart
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More about Travel chartMore about Travel chart
• Always a square
• A column at (m,n) is checked only when there is a direct movement from station at m to station at n direct.
• The number of times a column at (m,n) is checked over a period of time gives the frequency of movement of a worker or material.
• The matrix is always a symmetrical matrix.
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FLOW DIAGRAM FLOW DIAGRAM (4/6)(4/6)
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ACTIVITY DIAGRAMACTIVITY DIAGRAM
• Multiple activity chart is a chart on which the activities of more than one subject (workers, machine or item of equipment) are each recorded on a common time scale to show their inter relationship.
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ACTIVITY DIAGRAMACTIVITY DIAGRAM……
• No such time scales are used in the charts we saw previously.
• Can be used equally effectively even if there is no movement of workers. Primary focus, if movement of workers is there, is to identify the idle time on the part of either the workers or the machines.
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MULTIPLE ACTIVITY CHARTMULTIPLE ACTIVITY CHART
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TEMPLATE MODELSTEMPLATE MODELS
• Template models are used to study the layout and the positioning of various machines by pasting templates on the plant layout diagram.
• This can be extended by using the string diagram technique to visualize the flow of the material.
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A String Diagram Storing Tiles (Original Method)
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A String Diagram Storing Tiles (Improved Method)
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Flow Diagram Serving Dinners in a Hospital Ward
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Flow Process Chart – Man Type Dinners in a Hospital Ward
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Having located the departments and the equipments to be stationed within the
department, the layout process is generally a trial and process keeping the principles of layout and material
handling in mind.
Layout of work stationsLayout of work stations
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1. Locate key operations
2. Locate main gangways
3. Avoid back tracking/crisis crossing
4. Locate doorways (in/exit)
5. Locate remaining work areas
6. Locate minor gangways / aisles
7. Locate the departments and sections with the plant & matching
8. Complete location of subsidiary equipments (materials, tool boxes, scrap bins, telephones, electric panels)
9. Check final layout against companies general policies and specifications.
Planning SequencePlanning Sequence
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References References
• “Introduction to Work Study”, chapter 10, pages 110-130, International Labour Office, Geneva – Publisher: Raju Primlani for Oxford & IBH
Publishing Co. Pvt. Ltd., New Delhi.
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